Economy & Market

Stepping Up Sustainability

Published

1 year ago

November 23, 2024

Roshna

Supplementary Cementitious Materials (SCMs) offer a sustainable way to reduce cement usage, enhance concrete durability and lower the environmental impact of construction. ICR discusses integrating industrial byproducts like fly ash and slag as SCMs support resource conservation, cost savings, and long-lasting infrastructure.

The construction industry is at a pivotal juncture, facing increasing pressure to adopt sustainable practices amidst growing environmental concerns. As a major contributor to global greenhouse gas emissions, the industry recognises the urgent need for innovative solutions to minimise its ecological footprint. One such solution is the use of Supplementary Cementitious Materials (SCMs), which have emerged as vital components in the quest for sustainable concrete production. SCMs not only reduce the reliance on Portland cement—one of the most significant contributors to carbon emissions in construction—but also enhance the performance and durability of concrete.
According to a research report published by Spherical Insights & Consulting, the Global Supplementary Cementitious Materials Market Size is Expected to Grow from USD 25.40 Billion in 2023 to USD 47.70 Billion by 2033, at a CAGR of 6.50 per cent during the forecast period 2023-2033. Asia Pacific is estimated to hold the largest share of the supplementary cementitious materials market over the forecast period.
The market for supplementary cementitious materials is experiencing rapid growth, driven by factors such as rapid/fast-paced urbanisation and infrastructure development in emerging economies like China, India, Malaysia, and Singapore. Supportive policies and regulations, coupled with rising demand for durable concrete with lower penetrability, are key drivers impelling the surge in demand for supplementary cementitious materials.

Understanding SCMs
SCMs are materials that can be used to replace a portion of Portland cement in concrete. They react with calcium hydroxide to form additional cementitious compounds, thereby enhancing the concrete’s properties. SCMs include a variety of materials, such as fly ash, ground granulated blast-furnace slag (GGBS), silica fume and natural pozzolans.

Fly ash: Fly ash is a byproduct from burning pulverised coal in electric power generating plants. It is collected from the flue gases and is commonly used in concrete due to its pozzolanic properties. Fly ash can improve workability, reduce water demand, and enhance long-term strength and durability. Its fine particles fill voids within the concrete matrix, resulting in a denser and more impermeable material.
In an authored article by Dr Supradip Das, Vice Chairman, CED 41 (BIS), for NBM&CW, he points out that compared to cement and water, the chemical reaction between fly ash and calcium hydroxide occurs at a slower pace, leading to a delayed setting time in concrete, which promotes enhanced hardening. He explains how this slower hardening, together with the varying properties of fly ash, can present substantial challenges in concrete production. In India, ash ponds currently occupy approximately 65,000 acres, and fly ash production is projected to exceed 235 million tonnes by 2024, he elaborates.
GGBS: This material is obtained by rapidly cooling molten iron slag from a blast furnace with water or steam. GGBS is known for its high strength and durability, particularly in aggressive environments where concrete is exposed to chlorides or sulphates. It not only enhances the concrete’s mechanical properties but also contributes to its resistance to corrosion and shrinkage.
Silica fume: Silica fume is a byproduct of the production of silicon metal or ferrosilicon alloys. It is extremely fine, with a particle size much smaller than that of cement. When added to concrete, silica fume significantly increases strength, reduces permeability, and enhances durability. Its high silica content promotes additional pozzolanic reactions, leading to a denser concrete matrix.
Natural pozzolans: Natural pozzolans, such as volcanic ash and pumice, have been used in construction for centuries. They react with calcium hydroxide in the presence of moisture to form compounds with cementitious properties. These materials are particularly valuable in regions where volcanic ash is abundant, as they are sustainable alternatives that can improve concrete’s performance.

Benefits of Using SCMs
The incorporation of SCMs into concrete mixtures offers numerous benefits that align with sustainable construction practices:

Enhanced durability: Concrete containing SCMs exhibits improved durability characteristics, including increased resistance to sulfate attack, reduced permeability, and enhanced longevity. This durability translates into lower maintenance costs and longer service life for structures.
Reduced carbon footprint: The use of SCMs significantly decreases the amount of Portland cement required in concrete. As cement production is responsible for approximately 8 per cent of global CO2 emissions, reducing its usage through SCMs can lead to substantial reductions in greenhouse gas emissions.
Improved workability: SCMs like fly ash improve the workability of fresh concrete, making it easier to place and finish. This can lead to enhanced productivity on construction sites and reduced labour costs.
Cost-effectiveness: By substituting a portion of cement with SCMs, construction projects can achieve cost savings. Fly ash and GGBS, being industrial byproducts, are often more affordable than Portland cement.
Waste Utilisation: The use of SCMs promotes recycling and waste reduction. By utilising industrial byproducts such as fly ash and slag, the construction industry can contribute to a circular economy.

Vimal Joshi, Assistant General Manager – Quality Control, Wonder Cement, says, “SCMs like fly ash, slag and silica fume significantly enhance the durability and strength of concrete, particularly under diverse environmental conditions. Fly ash improves workability and extends the setting time, making it ideal for mass concrete projects and hot climates. The fine particles fill voids in the cement matrix, reducing permeability and enhancing resistance to sulphate and chloride attack, thus increasing durability. Slag, with its slow hydration properties, improves long-term strength and is particularly effective in reducing thermal cracking in massive concrete structures. It also enhances resistance to aggressive chemicals, making it suitable for marine environments and industrial applications.”
“Silica fume, known for its ultrafine particles, increases the density of concrete, boosting both compressive strength and durability, especially in harsh environments. By incorporating SCMs, we create concrete that is more resilient to environmental stressors, ensuring longer-lasting structures with reduced maintenance needs” he adds.

Sustainable construction
Sustainable construction practices are increasingly prioritised due to their environmental, social and economic impact. SCMs play a pivotal role in this paradigm shift. By integrating SCMs into concrete production, the construction industry can achieve:

Reduced resource consumption: By minimising the reliance on virgin materials, SCMs contribute to the conservation of natural resources. This is particularly important in regions where natural aggregates and raw materials are scarce.
Promotion of circular economy: The use of byproducts like fly ash and slag exemplifies a circular economy approach, where waste materials are repurposed for new applications. This not only reduces landfill waste but also promotes sustainable sourcing practices.
Alignment with green building certifications: Many green building rating systems, such as LEED (Leadership in Energy and Environmental Design), encourage the use of SCMs. By incorporating these materials, projects can earn credits for sustainability, making them more appealing to environmentally conscious clients.

Tushar Khandhadia, General Manager – Production, Udaipur Cement Works, says, “SCMs provide an environmentally friendly alternative to traditional Portland cement by reducing the amount of clinker required to produce cement. Clinker is the main ingredient in Portland cement and is produced by heating limestone and other raw materials to high temperatures, which releases significant GHG emissions. Thus, by using SCMs, less clinker is required, thereby reducing GHG emissions, energy use and the environmental impact of cement production. Some SCMs such as fly ash and slag are by-products of other industrial processes, meaning that their use in cement production reduces waste and enhances resource efficiency. Moreover, the use of SCMs can enhance the properties of concrete, thereby increasing its durability and service life which helps to further reduce the overall embodied carbon of the structure.”

“In short, the use of SCMs contributes to reducing the carbon footprint of cement production by improving the efficiency of resource utilisation and reducing greenhouse gas (GHG) emissions during the production process. This has led to an increased demand for SCMs in the construction industry, as environmental concerns and sustainable development goals have become more prominent factors in the selection of building materials,” he adds.

Performance Characteristics of SCMs
The performance characteristics of concrete are significantly enhanced when SCMs are incorporated. Key attributes include:

Increased Compressive Strength: Studies have demonstrated that concrete containing SCMs, particularly silica fume and GGBS, can achieve higher compressive strengths compared to conventional concrete mixtures. This is crucial for high-performance applications, such as high-rise buildings and infrastructure.

Dr SB Hegde, Professor, Jain College of Engineering and Technology, Hubli, and Visiting Professor, Pennsylvania State University, USA states, “The raw mix plays a vital role in clinker formation. A high liquid phase due to improper ratios of silica, alumina, and iron oxide can lead to excessive melting. Controlling the silica modulus (SM: 2.3-2.7) and alumina modulus (AM: 1.3-1.8) ensures a more stable clinker and reduces the risk of red river formation. If the raw mix is improperly proportioned, red river formation becomes more likely due to high fluxing compounds that melt at lower temperatures. The occurrence of red river has numerous negative impacts on both clinker quality and kiln performance.”

Reduced permeability: SCMs improve the density of the concrete matrix, leading to reduced permeability. This characteristic is vital for structures exposed to harsh environmental conditions, as it minimises water ingress and subsequent damage.
Altered hydration kinetics: The presence of SCMs can influence the hydration process of cement, often resulting in a slower but more sustained release of heat. This is beneficial in mass concrete applications where heat buildup can lead to cracking.
Long-term strength development: Concrete containing SCMs typically exhibits improved long-term strength characteristics. While initial strength development may be slower, the overall strength continues to increase over time as the pozzolanic reactions progress.

Guidelines and Standards
The effective use of SCMs in concrete is governed by various guidelines and standards. In India, the Bureau of Indian Standards (BIS) has established specific specifications for the use of fly ash and GGBS in concrete.

IS 456:2000: This Indian Standard provides general guidelines for the use of SCMs in concrete and outlines performance requirements to ensure the quality of construction materials. Adherence to these standards is crucial for maintaining the integrity and performance of concrete.
IS 1489 (Part 1 and Part 2): These standards specifically address the use of fly ash and GGBS, providing criteria for their quality, chemical composition, and performance in concrete.

Following these guidelines ensures that SCMs contribute positively to concrete performance, supporting the construction of durable and sustainable structures.

Challenges in SCM Adoption
Despite their numerous advantages, several challenges hinder the widespread adoption of SCMs in India:

Quality variability: The quality of SCMs can vary significantly depending on their source and production methods. This variability can lead to inconsistencies in concrete performance, necessitating rigorous quality control measures.
Regulatory barriers: A lack of comprehensive regulations and standards for SCMs can impede their acceptance and use in construction projects. Greater clarity and uniformity in regulations would facilitate broader adoption.
Compatibility issues: Different types of cement and SCMs may not always be compatible, leading to challenges in mix design. It is essential to conduct thorough testing to ensure that the chosen SCMs integrate well with the cement used in a specific project.

Shreesh A Khadilkar, Consultant and Advisor, and Former Director Quality and Product Development, ACC says, “Clinkers with good reactivity are observed to show 1 Day strengths in lab ground cements of 30 to 35 MPa. Higher values being observed when clinker alkali sulphates are high (especially with Petcoke as fuel), the achieved Blaine’s and quantity of nibs removed from the lab ground cement, in the fixed grinding time is also indicative of clinker grindability. Judicious raw mix optimisation with existing or alternative corrective materials (with the fuel mix used by the plant) can be attempted so as to have a clinker with improved reactivity/hydraulic potential. In a running plant the approach has to be by attempting small gradual changes to clinker composition and assessing the impact of the changes, on kiln performance and clinker quantity.”
Awareness and training: There is a need for increased awareness and training among construction professionals regarding the benefits and proper use of SCMs. Educating stakeholders can drive their acceptance and utilisation.

Successful Applications of SCMs
Several projects across India have successfully demonstrated the benefits of using SCMs, showcasing their effectiveness in enhancing concrete performance while reducing environmental impact:

Delhi Metro Rail Corporation (DMRC): In the construction of the DMRC, high volumes of fly ash were used to produce concrete. This decision resulted in substantial cost savings, improved workability, and reduced environmental impact. The use of SCMs also contributed to the project’s overall sustainability goals.
Narmada River Valley Project: In this project, GGBS was incorporated into the concrete mix, enhancing the durability and longevity of structures exposed to the water-saturated environment. The use of GGBS ensured that the concrete could withstand the harsh conditions prevalent in the region, reducing maintenance needs and extending the service life of the structures.

These case studies illustrate the practical benefits of using SCMs in large-scale construction projects, reinforcing their viability as sustainable alternatives.

Future Trends in SCM Use
As the Indian cement industry evolves, several trends are expected to shape the future of SCM utilisation:

Innovations in materials: Research into new SCMs, such as bio-based materials and advanced pozzolans, is on the rise. These innovations may expand the range of materials available for sustainable concrete production, providing more options for construction professionals.
Increased awareness: Growing awareness among construction professionals about the benefits of SCMs is likely to drive their adoption. Workshops, seminars, and training programs can play a crucial role in educating stakeholders about proper mix design and applications.
Government support: Policymakers can promote the use of SCMs by offering incentives for sustainable construction practices. This can include subsidies, tax breaks, or recognition for projects that utilise SCMs, encouraging broader acceptance.
Technological advancements: Advances in technology may facilitate better quality control, enabling more consistent production of SCMs and improving their integration into concrete mixtures.

Conclusion
SCMs represent a vital component in the transition toward more sustainable concrete production. By incorporating these materials, the Indian cement industry can significantly reduce its carbon footprint, enhance concrete performance, and contribute to a circular economy. While challenges remain, the benefits of SCMs far outweigh the drawbacks, making them an essential element in the future of sustainable construction. As awareness grows
and innovations emerge, SCMs are poised to play an even more significant role in shaping a greener built environment.

– Kanika Mathur

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Filtration Technology is Critical for Efficient Logistics

Published

3 days ago

May 15, 2026

admin

Niranjan Kirloskar, MD, Fleetguard Filters, makes the case that filtration technology, which has been long treated as a routine consumable, is in fact a strategic performance enabler across every stage of cement production and logistics.

India’s cement industry forms the core for infrastructure growth of the country. With an expected compound annual growth rate of six to eight per cent, India has secured its position as the second-largest cement producer globally. This growth is a result of the increasing demand across, resulting in capacity expansion. Consequently, cement manufacturers are now also focusing on running the factories as efficiently as possible to stay competitive and profitable.
While a large portion of focus still remains on production technologies and capacity utilisation, the hidden factor in profitability is the efficiency of cement logistics. The logistics alone account for nearly 30 per cent to 40 per cent of the total cost of cement, making efficiency in this segment a key lever for profitability and reliability.
In the midst of this complex and high-intensity ecosystem, filtration often remains one of the most underappreciated yet essential enablers of performance.

A demanding operational landscape
Cement production and logistics inherently operate in some of the harshest industrial environments. With processes such as quarrying, crushing, grinding, clinker production, and bulk material handling expose the machinery to constant high temperatures, heavy loads, and dust, often the silent destructive force for engines.
The ecosystem is abrasive, and often one with a high contamination index. These challenging conditions demand equipment such as the excavators, crushers, compressors, and transport vehicles to perform and perform efficiently. The continuous exposure to contamination across every aspect like air, fuel, lubrication, and even hydraulic systems causes long-term damage. Studies have also shown that 70 to 80 per cent of hydraulic system failures are directly linked to contamination, while primary cause of engine wear is inadequate air filtration.
For engines as heavy as these, even a minor contaminant has a cascading effect; reducing efficiency, performance and culminating to unplanned downtime. Particles as small as 5 to 10 microns, far smaller than a human hair (~70 microns), can cause significant damage to critical engine components. In an industry where margins are closely linked to operational efficiency, such disruptions can significantly affect both cost structures and delivery timelines.

Dust management: A persistent challenge
Dust is a natural by-product in cement operations. From drilling and blasting in the quarries to packing in plants, this fine particulate matter does occupy a large space in operations. Dust concentration levels in quarry and crushing zones often create extremely high particulate exposure for equipment. These fine particles, when enter the engines and critical systems, accelerates the wear and tear of the component, affecting directly the operational efficiency. Over time every block fall; engine performance declines, fuel consumption rises, and maintenance cycles shorten. In this case, effective air filtration is the natural first line of defence. Advanced filtration systems are designed to capture high volumes of particulate matter while maintaining consistent airflow, ensuring that engines and equipment operate under optimal conditions.
In high-dust applications, as in cement production, even the filtration systems are expected to sustain performance over extended periods without the need of frequent replacement. This becomes crucial in remote quarry locations where access to frequent maintenance may be limited.

Fluid cleanliness and system integrity
Beyond air filtration, fluid systems also play a crucial role for equipment reliability in cement operations. Fuel systems are required to remain free from contaminants for efficient working of combustion and injection protection. Additionally, lubrication systems also need to maintain the oil purity to reduce friction and prevent any premature wear of moving parts. The hydraulic systems, which are key to several heavy equipment operations, are especially sensitive to contamination.
If fine particles or water enters these systems, it can lead to reduced efficiency, erratic performance, and eventual failure of the system. Modern filtration systems are designed with high-efficiency media capable of removing extremely fine contaminants, with advanced fuel and oil filtration solutions filtering particles as small as two to five microns. Multi-stage filtration systems further ensure that fluid performance is maintained even under challenging operating conditions.
Another critical aspect of fuel systems is water separation. Removing moisture helps prevent corrosion, improves combustion efficiency and enhances overall engine reliability. Modern water separation technologies can achieve over 95 per cent efficiency in removing water from fuel systems.

Ensuring reliability across the value chain
Filtration plays a critical role across every stage of cement logistics:
• Quarry operations: Equipment operates in highly abrasive environments, requiring strong protection against dust ingress and hydraulic contamination.
• Processing units: Crushers, kilns, and grinding mills depend on clean lubrication and cooling systems to sustain continuous operations.
• Material handling systems: Pneumatic and mechanical systems rely on clean air and fluid systems for efficiency and reliability.
• Transportation networks: Bulk carriers and trucks must maintain engine health and fuel efficiency to ensure timely deliveries.
Across these operations, filtration plays a vital role; as it supports consistent equipment performance while reducing the risk of unexpected failures.
Effective filtration solutions can reduce unscheduled equipment failures by 30 to 50 per cent across heavy-duty operations.

Uptime as a strategic imperative
In cement manufacturing, uptime is currency. Downtime not only delays the production, but it also greatly impacts the supply commitments and logistics planning. With the right filtration systems, contaminants are kept at bay from entering the
critical systems, and they also significantly extend the service intervals.
Optimised filtration can extend service intervals by 20 to 40 per cent, reducing maintenance frequency while maintaining consistent performance across demanding operating conditions. Filtration systems designed for heavy-duty applications sustain efficiency throughout their lifecycle, ensuring reliable protection with minimal interruptions. This leads to improved equipment availability, lower maintenance costs, and more predictable operations, with well-maintained systems capable of achieving uptime levels of over 90 to 95 per cent in challenging cement environments.

Supporting emission and sustainability goals
With the rising environmental awareness, the cement industry too is aligning with the stricter norms and sustainability targets. In this scenario, the operational efficiency is directly linked to emission control.

Air and fuel systems that are clean enable
much more efficient combustion. They also reduce emissions from both the stationary equipment and transport fleets. Similarly, with a well-maintained fluid cleanliness, emission systems function better. Poor combustion due to contamination can increase emissions by 5 to 10 per cent, making clean systems critical for compliance.
Additionally, efficient and longer lasting filtration systems significantly reduce any waste generation and contribute to increased sustainable maintenance practices. Extended-life filtration solutions can reduce filter disposal and maintenance waste by 15 to 20 per cent. Smart and efficient filtration in this case plays an important role in meeting the both regulatory and environmental objectives within the industry.

Advancements in filtration technology
Over the years, there has been a significant evolution in the filtration technology to meet the modern industrial applications.
Key developments include:
• High-efficiency filtration media capable of capturing very fine particles without restricting flow
• Compact and integrated designs that combine multiple filtration functions
• Extended service life solutions that reduce replacement frequency and maintenance downtime
• Application-specific engineering tailored to different stages of cement operations
Modern multi-layer filtration media can improve dust-holding capacity by up to two to three times compared to conventional systems, while maintaining consistent performance. These advancements have transformed filtration from a basic maintenance component into a critical performance system.

Adapting to diverse operating conditions
The cement industry of India operates across diverse geographies. Spanning across regions with arid regions with higher dust levels, to the coastal areas with higher humidity, challenges of each region pose different threats to the engines. Modern filtration systems are thus tailored to address these unique challenges of each region.
Indian operating environments often range from 0°C to over 50°C, with some of the highest dust loads globally in mining zones.
Additionally, filtration technology can also be customised to variations which then align the system design with factors like dust load, temperature, and equipment usage patterns. Equipment utilisation levels in India are typically higher than global averages, making robust filtration even more critical. This approach ensures optimal performance and durability across different operational contexts.

Impact on total cost of ownership
Filtration has a direct and measurable impact on the total cost of ownership of equipment.
Effective filtration leads to:
• Lower wear and tear on critical components
• Reduced maintenance and repair costs
• Improved fuel efficiency
• Extended equipment life
• Higher operational uptime
Effective filtration can extend engine life by 20 to 30 per cent and reduce overall maintenance costs by 15 to 25 per cent over the equipment lifecycle. These benefits collectively enhance productivity and reduce lifecycle costs. Conversely, inadequate filtration can result in frequent breakdowns, increased maintenance expenditure, and reduced asset utilisation.

Building a more efficient cement ecosystem
With the rising demand across various sectors, the cement industry is expected to expand at an unprecedented rate. This growth is forcing the production to move towards a more efficient and resilient system of operations. This requires attention not only to production technologies but also to the supporting systems that enable consistent performance. Filtration must be viewed as a strategic investment rather than a routine consumable. By ensuring the cleanliness of air and fluids across systems, it supports reliability, efficiency, and sustainability.

The road ahead
The future of cement logistics will be shaped by increasing mechanisation, digital monitoring, and stricter environmental standards. The industry is also witnessing a shift towards predictive maintenance and condition monitoring, where filtration performance is increasingly integrated with real-time equipment diagnostics.
In this evolving landscape, the role of filtration will become even more critical. As equipment becomes more advanced and operating conditions more demanding, the need for precise contamination control will continue to grow. From quarry to construction site, filtration technology underpins the performance of every critical system. It enables equipment to operate efficiently, reduces operational risks, and supports the industry’s broader goals of growth and sustainability. In many ways, it is the unseen force that keeps the cement ecosystem moving, quietly ensuring that every link in the value chain performs as expected.

About the author
Niranjan Kirloskar, Managing Director, Fleetguard Filters, is focused on driving innovation, operational excellence, and long-term business growth through strategic and people-centric leadership. With a strong foundation in ethics and forward-thinking decision-making, he champions a culture of collaboration, accountability, and technological advancement.

Concrete

Cement’s Next Fuel Shift

Published

3 days ago

May 15, 2026

admin

Jignesh Kindaria highlights how Thermal Substitution Rate (TSR) is emerging as a critical lever for cost savings, decarbonisation and competitive advantage in the cement industry.

India is simultaneously grappling with two crises: a mounting waste emergency and an urgent need to decarbonise its most carbon-intensive industries. The cement sector, the second-largest in the world and the backbone of the nation’s infrastructure ambitions, sits at the centre of both. It consumes enormous quantities of fossil fuel, and it has the technical capacity to consume something else entirely: the waste our cities cannot get rid of.
According to CPCB and NITI Aayog projections, India generates approximately 62.4 million tonnes of municipal solid waste annually, with that figure expected to reach 165 million tonnes by 2030. Much of this waste is energy-rich and non-recyclable. At the same time, cement kilns operate at material temperatures of approximately 1,450 degrees Celsius, with gas temperatures reaching 2,000 degrees. This high-temperature environment is ideal for co-processing, ensuring the complete thermal destruction of organic compounds without generating toxic residues. The physics are in our favour. The infrastructure is not.
Pre-processing is not the support act for co-processing. It is the main event. Get the particle size wrong, get the moisture wrong, get the calorific value wrong and your kiln thermal stability will suffer the consequences.

The regulatory push is real
The Solid Waste Management (SWM) Rules 2026 mandate that cement plants progressively replace solid fossil fuels with Refuse-Derived Fuel (RDF), starting at a 5 per cent baseline and scaling to 15 per cent within six years. NITI Aayog’s 2026 Roadmap for Cement Sector Decarbonisation targets 20 to 25 per cent Thermal Substitution Rate (TSR) by 2030. Beyond compliance, every tonne of coal replaced by RDF generates measurable carbon reductions which is monetisable under India’s emerging Carbon Credit Trading Scheme (CCTS). TSR is no longer a sustainability metric. It is a financial lever.
Yet our own field assessments across multiple Indian cement plants reveal a sobering reality: the primary barrier to scaling AFR adoption is not waste availability. It is the fragmented and under-engineered pre-processing ecosystem that sits between the waste and the kiln.

Why Indian waste is a different engineering problem
Indian municipal solid waste is not the material that imported shredding equipment was designed for. Our waste streams frequently exceed 40 per cent to 50 per cent moisture content, particularly during monsoon cycles, saturated with abrasive inerts including sand, glass, and stone. Plants relying on imported OEM equipment face months of downtime awaiting proprietary spare parts. Machines built for segregated, low-moisture waste fail quickly and disrupt the entire pre-processing operation in Indian conditions.
The two most common failures we observe are what I call the biting teeth problem and the chewing teeth problem. Plants relying solely on a primary shredder reduce bulk waste to large fractions, but the output remains too coarse for stable kiln combustion. Others attempt to use a secondary shredder as a standalone unit without a primary stage to pre-size the feed, leading to catastrophic mechanical failure. When both stages are present but mismatched in throughput capacity, the system becomes a bottleneck. Achieving the 40 to 70 tonnes per hour required for meaningful coal displacement demands a precisely coordinated two-stage process.

Engineering a made-in-India answer
At Fornnax, our response to these challenges is grounded in one principle: Indian waste demands Indian engineering. Our systems are built around feedstock homogeneity, the holy grail of kiln stability. Consistent particle size and predictable calorific value are the foundation of stable kiln combustion. Without them, no TSR target is achievable at scale.
Our SR-MAX2500 Dual Shaft Primary Shredder (Hydraulic Drive) processes raw, baled, or loosely mixed MSW, C&I waste, bulky waste, and plastics, reducing them to approximately 150 mm fractions at throughputs of up to 40 tonnes per hour. The R-MAX 3300 Single Shaft Secondary Shredder (Hydraulic Drive), introduced in 2025, takes that primary output and produces RDF fractions in the 30 to 80 mm range at up to 30 tonnes per hour, specifically optimised for consistent kiln feeding. We have also introduced electric drive configurations under the SR-100 HD series, with capacities between 5 and 40 tonnes per hour, already operational at a leading Indian waste-processing facility.
Looking ahead, Fornnax is expanding its portfolio with the upcoming SR-MAX3600 Hydraulic Drive primary shredder at up to 70 tonnes per hour and the R-MAX2100 Hydraulic drive secondary shredder at up to 20 tonnes per hour, designed specifically for the large-scale throughput that higher TSR ambitions require.

The investment case is now
The 2070 Net-Zero target is not a distant goal for India’s cement sector. It starts today, with decisions being made on the plant floor.
The SWM Rules 2026 are already in effect, requiring cement plants to replace coal with RDF. Carbon credit markets are opening up, and coal prices are not going to get cheaper. Every tonne of coal a cement plant replaces with waste-derived fuel saves money on one side and generates carbon credit revenue on the other. Pre-processing infrastructure is no longer just a compliance requirement. It is a business investment with a measurable return.
The good news is that nothing is missing. The technology works. The waste is available in every Indian city. The government has provided the policy direction. The only thing standing between where the industry is today and where it needs to be is the commitment to build the right infrastructure.
The cement companies that move now will not just meet the regulations. They will be ahead of every competitor that waits.

About the author
Jignesh Kundaria is the Director and CEO of Fornnax Technology. Over an experience spanning more than two decades in the recycling industry, he has established himself as one of India’s foremost voices on waste-to-fuel technology and alternative fuel infrastructure.

Concrete

Dalmia Bharat Cement launches water repellent cement brand Weather 365 in Eastern India

Published

3 days ago

May 15, 2026

admin

The company has introduced water repellent cement to target rising consumer demand for weather-resilient housing solutions.

New Delhi, May 15, 2026

Dalmia Bharat Cement, one of India’s leading cement manufacturing companies, has launched Weather 365, a new super-premium water repellent cement brand aimed at addressing growing consumer demand for durable, weather-resistant construction materials in Eastern India. The product is positioned as a high-performance offering for consumers seeking long-term protection against seepage, dampness and moisture damage. The launch marks a strategic push by Dalmia Bharat Cement into the fast-growing premium cement segment, where consumer preference is increasingly shifting from price-led purchases to specialised, performance-oriented building materials.

Reinforcing its super-premium positioning, the product will be available in premium-quality water-resistant and tamper-proof BOPP packaging. ‘Weather 365’ will be introduced across its retail markets in West Bengal and Bihar.

In addition to the product rollout, the company will provide on-site technical support through its engineering and technical services teams to guide customers on best construction practices and improve long-term building performance.

Speaking on the launch, company spokesperson from Dalmia Bharat Cement said: “Weather 365 is a testament to Dalmia Bharat Cement’s relentless pursuit of innovation. Eastern India experiences prolonged monsoons, high humidity and challenging weather conditions that significantly impact the life of buildings and homes. Consumers today are actively looking for solutions that offer long-term protection and lower maintenance costs. Weather 365 is our answer to that need – a differentiated premium product that combines structural strength with advanced moisture protection that safeguards homes at every level, every season. We believe this category will see strong growth in the coming years.”

Weather 365 is a specialised cement product developed to meet the rigorous demands of modern construction in regions exposed to high humidity, heavy rainfall and extreme weather cycles. Designed for roofs, columns and foundations, it delivers end-to-end moisture protection across the entire home from the structure’s core to its visible surfaces. Its proprietary uniform water repellent technology helps reduce water penetration, minimize steel corrosion in RCC structures while preventing efflorescence and damp patches, thereby ensuring stronger concrete, improved paint life and long-lasting structural health. Positioned as a super-premium product in Dalmia Bharat Cement’s portfolio, Weather 365 targets discerning homeowners, contractors and builders who seek the best-in-class protection for their construction investments.

With a strong manufacturing and market presence across Eastern India, Dalmia Bharat Cement continues to strengthen its footprint in one of its key strategic markets. As the company advances towards its vision of becoming a pan-India cement leader, it remains focused on delivering innovative, premium construction solutions tailored to evolving consumer needs.

Dalmia Bharat Cement, a subsidiary of Dalmia Bharat Limited, is a leading player in the cement manufacturing segment and has been in existence since 1939. It is the first cement company to commit to RE100, EP100 & EV100 (first triple joiner) – showing real business leadership in the clean energy transition by taking a joined-up approach. With a growing capacity, currently pegged at 49.5 million tonne, Dalmia Bharat Cement is the fourth-largest cement manufacturing group in India by installed capacity. Spread across ten states and fifteen manufacturing units, the company is a category leader in super-specialist cement used for oil well, railway sleepers and airstrips and is the country’s largest producer of Portland Slag Cement (PSC).